Lincoln Electric SVM125-A User manual

SVM125-A

October 1996

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be

increased by proper installation .

. . and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before

you act and be careful.

SERVICE MANUAL

World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

For use with machine code numbers 9805 to 10220

CLASSIC II

TM

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SAFETY

i i

CLASSIC II

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop

the engine and allow it to cool before refuel-

ing to prevent spilled fuel from vaporizing on

contact with hot engine parts and igniting. Do

not spill fuel when filling tank. If fuel is spilled,

wipe it up and do not start engine until fumes

have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers

and devices in position and in good

repair.Keep hands, hair, clothing and tools

away from V-belts, gears, fans and all other

moving parts when starting, operating or

repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle con-

trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you

purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,

Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the

Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

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SAFETY

ii ii

CLASSIC II

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a.Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

to

form phosgene, a highly toxic gas, and other irritating

products.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

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CLASSIC II

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can

cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate circuits.

This can create fire hazards or overheat lifting chains or

cables until they fail.

6.h. Also see item 1.c.

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SAFETY

iv iv

CLASSIC II

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met-

allique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc-

tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud-

er parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soud

e pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de

la zone de travail qu’il est pratique de le faire. Si on place la

masse sur la charpente de la construction ou d’autres endroits

éloignés de la zone de travail, on augmente le risque de voir

passer le courant de soudage par les chaines de levage,

câbles de grue, ou autres circuits. Cela peut provoquer des

risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir

le code “Code for safety in welding and cutting” CSAStandard

W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ‘93

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

CLASSIC II

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Pre-operation Engine Service.....................................................................................................A-4

Electrical Output Connections.....................................................................................................A-6

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications........................................................................................................B-3

Operational Features and Controls.............................................................................................B-3

Design Features..........................................................................................................................B-3

Welding Capability ......................................................................................................................B-4

Limitations .................................................................................................................................B-4

Controls and Settings..................................................................................................................B-5

Engine Operation........................................................................................................................B-8

Welding Operation ....................................................................................................................B-10

Auxiliary Power .........................................................................................................................B-13

Accessories ..........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance.............................................................................................D-2

Major Component Locations.......................................................................................................D-8

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual ................................................................................................................................P-219

RETURN TO MAIN INDEX

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TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1 Section A-1

CLASSIC II

Installation

Technical Specifications..............................................................................................................A-2

Input – Diesel Engine ...........................................................................................................A-2

Rated Output – Welder.........................................................................................................A-2

Output – Welder and Generator...........................................................................................A-2

Physical Dimensions.............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Storing .................................................................................................................................A-3

Stacking................................................................................................................................A-4

Tilting .................................................................................................................................A-4

Lifting .................................................................................................................................A-4

High Altitude Operation.........................................................................................................A-4

Pre-operation Engine Service.....................................................................................................A-4

Oil ........................................................................................................................................A-4

Fuel.......................................................................................................................................A-4

Battery Connections .............................................................................................................A-4

Muffler .................................................................................................................................A-5

Spark Arrester.......................................................................................................................A-5

Undercarriages.....................................................................................................................A-5

Electrical Output Connections.....................................................................................................A-6

Welding Cable Connections.................................................................................................A-6

Cable Installation, Polarity Control, and Cable Sizes..............................................A-6

Machine Grounding ..............................................................................................................A-7

Auxiliary Power Receptacles, Plugs, and Hand-held Equipment.........................................A-7

Circuit Breakers....................................................................................................................A-7

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INSTALLATION

A-2 A-2

CLASSIC II

TECHNICAL SPECIFICATIONS - CLASSIC II

INPUT - DIESEL ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

Deutz 3 cyl., 1725 RPM 125 cu. in. Electric Fuel: 15 gal.

F3L-1011F Air-cooled Full load (2049 cc) (57 liters)

diesel Oil: 6.3 qt.

28 HP @ 1800 RPM (6.0 liters)

1700 RPM High idle

1350 RPM

Low idle

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes

100% Duty Cycle 200 DC Constant Current 28V

60% Duty Cycle 250 DC Constant Current 40V

40% Duty Cycle 300 DC Constant Current 32V

OUTPUT - WELDER AND GENERATOR

Welding Ranges Max. Open Circuit Voltage Auxiliary Power

(1)

40-325 Amps DC 98.5 3.0 kVA of 115/230 V, 60Hz Power

26 Amps @ 115 V

13 Amps @ 230 V

PHYSICAL DIMENSIONS

Height Width Depth Weight

49.94 in. 24 in. 60 in. 1340 lb.

1040 mm 610 mm 1524 mm 608 kg

1

CSA machines can draw 15 amps from either half of the receptacle. Non-CSA machines can draw 20 amps from either half of the

receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.

Read this entire installation section before you

start installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you have

thoroughly read all the operation and maintenance

manuals supplied with your machine. They include

important safety precautions; detailed engine starting,

operating, and maintenance instructions; and parts

lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live

parts or electrodes with your

skin or wet clothing.

• Insulate yourself from the work

and ground.

• Always wear dry insulating

gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated

areas or vent exhaust to the out-

side.

• Do not stack anything on or near

the engine.

MOVING PARTS can injure.

• Do not operate this equipment

with any of its doors open or

guards off.

• Stop the engine before servicing

it.

• Keep away from moving parts.

See additional safety information at the front of this

manual.

Only qualified personnel should install, use, or ser-

vice this equipment.

LOCATION AND VENTILATION

Always operate the Classic II with the doors closed.

Leaving the doors open changes the designed air flow

and may cause overheating. Always operate the

welder with the case roof on and all machine compo-

nents completely assembled. This will protect you from

the dangers of moving parts, hot metal surfaces, and

live electrical devices.

Whenever you use the Classic II, be sure that clean

cooling air can flow through the machine’s diesel

engine and the generator. Avoid dusty, dirty areas.

Also, keep the machine away from heat sources. Do

not place the back end of the generator anywhere near

hot engine exhaust from another machine. And of

course, make sure that engine exhaust is ventilated to

an open, outside area.

The Classic II may be used outdoors. Do not set the

machine in puddles or otherwise submerge it in water.

Such practices pose safety hazards and cause improp-

er operation and corrosion of parts.

STORING

1. Store the machine in a cool, dry place when it is not

in use. Protect it from dust and dirt. Keep it where

it can’t be accidentally damaged from construction

activities, moving vehicles, and other hazards.

2. Drain the engine oil and refill with fresh 10W30 oil.

Run the engine for about five minutes to circulate oil

to all the parts. See the

Maintenance

section of

this manual for details on changing oil.

3. Remove the battery, recharge it, and adjust the

electrolyte level. Store the battery in a dry, dark

place.

4. See your engine operation manual for further infor-

mation on fuel and engine preservation.

INSTALLATION

A-3 A-3

CLASSIC II

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WARNING

STACKING

Classic II machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev-

er you use it or store it. Any surfaces you place it on

other than the ground must be firm, non-skid, and

structurally sound.

The diesel engine is designed to run in a level position

for best performance. If you do operate it at a slight

angle, be sure to check the oil regularly and keep the

oil level at the FULL mark as it would be in its normal

level condition. Also, fuel capacity will be a little less at

an angle.

LIFTING

The Classic II weighs 1340 lb./608 kg. A lift bail is

provided for lifting with a hoist.

FALLING EQUIPMENT can

cause injury.

Do not lift this machine using lift bail if

it is equipped with a heavy accessory

such as a trailer.

Lift only with equipment of adequate lifting capacity. Be

sure machine is stable when lifting.

HIGH ALTITUDE OPERATION

It may be necessary to derate welder output at higher

altitudes. Some engine adjustment may be required.

Contact a Deutz Service Representative.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the diesel

engine in the

Operation

and

Maintenance

sections of

this manual before you operate the Classic II.

Keep hands away from the engine muffler or HOT

engine parts.

• Stop the engine when fueling.

• Do not smoke when fueling.

• Remove the fuel cap slowly to release pressure.

• Do not overfill the fuel tank.

• Wipe up spilled fuel and allow the fumes to clear

before starting the engine.

• Keep sparks and flame away from the fuel tank.

OIL

The Classic II is shipped with the engine

filled with SAE 10W-30 oil (API class

CC/DO). This should be fine for most

ambient operating temperature conditions. See the

engine operation manual for specific recommenda-

tions. CHECK THE OIL LEVEL BEFORE YOU

START THE ENGINE. This is an added precaution.

When full, the oil level should be up to but not over the

FULL mark on the dipstick. If it is not full, add enough

oil to fill it to the full mark. DO NOT overfill.

NOTE: This unit is equipped with an Engine Protection

Package. An internal kill switch will shut down the

engine if the oil pressure drops below a minimum oper-

ating specification or if the oil temperature reaches an

excessive level.

For more oil fill and service information, see the

Maintenance

section of this manual.

FUEL

Fill the fuel tank with clean, diesel fuel only.

The Classic II has a 15 gallon (57 liter) fuel

tank with a top fill and fuel gauge mounted

on the control panel. See the

Operation

and

Maintenance

sections of this manual for more

details about fuel.

BATTERY CONNECTIONS

The Classic II is shipped with the negative

battery cable disconnected. Before you

operate the machine, make sure the

IGNITION switch is in the OFF position and attach the

disconnected cable securely to the battery terminal. If

the battery is discharged and won't start the engine,

see the battery charging instructions in the

Maintenance

section.

INSTALLATION

A-4 A-4

CLASSIC II

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WARNING

MUFFLER

This welder is supplied with an adjustable rain cap for

the muffler. Install the rain cap using the clamp provid-

ed with the outlet facing away from the direction in

which this unit will be transported. This will minimize

the amount of water and debris that could enter the

muffler during transportation.

SPARK ARRESTER

Diesel engine mufflers may emit sparks when the

engine is running. Some federal, state, or local laws

require spark arresters in locations where unarrested

sparks could present a fire hazard.

Standard mufflers (like the one included with the

Classic II) do not act as spark arresters. When local

laws require it, a spark arrester must be installed on the

machine and properly maintained. An optional spark

arrester kit is available for your Classic II. See the

Accessories

section of this manual for more informa-

tion.

An incorrect spark arrester may lead to damage to the

engine or reduce performance.

UNDERCARRIAGES

If you use a non-Lincoln undercarriage, you must

assume responsibility that the method of attachment

and usage does not result in a safety hazard nor dam-

age the welding equipment. Some of the factors to be

considered are as follows:

1. Design capacity of the undercarriage vs. the weight

of the Lincoln equipment and likely additional

attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue

stress to the framework.

3. Proper placement of the equipment on the under-

carriage to ensure stability side to side and front to

back. This includes when being moved and when

standing by itself for operation or service.

4. Typical conditions of use, such as travel speed,

roughness of the surfaces where the undercarriage

will be used, environmental conditions, likely main-

tenance.

5. Conformance with federal, state, and local laws.

Consult applicable federal, state, and local laws

about specific requirements for use on public high-

ways.

INSTALLATION

A-5 A-5

CLASSIC II

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CAUTION

ELECTRICAL OUTPUT

CONNECTIONS

See Figure A.1 for the location of the 115 and 230 volt

receptacles, weld output terminals, and ground stud.

WELDING CABLE CONNECTIONS

CABLE INSTALLATION, POLARITY CONTROL,

AND CABLE SIZES

With the engine off, route the electrode and work

cables through the strain relief bracket on the base and

connect to the terminals located below the fuel tank

mounting rail. (See size recommendations below.) For

positive polarity, connect the electrode cable to the ter-

minal marked Positive (+). For Negative polarity, con-

nect the electrode cable to the Negative (-) terminal.

These connections should be checked periodically and

tightened if necessary.

• Loose connections will cause the output terminals to

overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal

connection. Keep the cables isolated and separate

from one another.

When welding at a considerable distance from the

welder, be sure you use ample size welding cables.

Table A.1 lists recommended cable sizes and lengths

for rated current and duty cycle. Length refers to the

distance from the welder to the work and back to the

welder. Cable diameters are increased for long cable

lengths to reduce voltage drops.

Lincoln Electric offers a welding accessory kit with the

properly specified welding cables. See the

Accessories

section of this manual for more

information.

INSTALLATION

A-6 A-6

CLASSIC II

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CAUTION

1

3

5

2

FIGURE A.1 - CLASSIC II OUTPUT CONNECTIONS

1. 230 VOLT RECEPTACLE

2. 115 VOLT RECEPTACLE

3. WELD OUTPUT TERMINALS (2)

4. GROUND STUD (LOCATION)

5. CABLE STRAIN RELIEF BRACKET

TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

Cable sizes for combined length of

electrode plus work cable

Amps Duty Cycle Up to 200 ft. 200 to 250 ft.

200 100% 1 1/0

250 60% 1 1/0

300 40% 1/0 2/0

4

MACHINE GROUNDING

Because the Classic II creates its own

power from its diesel-engine driven gener-

ator, you do not need to connect the

machine frame to an earth ground.

However, for best protection against elec-

trical shock, connect a heavy gauge wire (#8 AWG or

larger) from the ground stud located on the welding

generator frame foot. (See Figure A.2) to a suitable

earth ground such as a metal pipe driven into the

ground. The US National Electrical Code lists a number

of alternate means of grounding electrical equipment.

Do not ground the machine to a pipe that carries

explosive or combustible material.

Some state, local, or other codes or unusual operating

circumstances may require the machine frame to be

grounded. It is recommended that you determine the

extent to which such requirements may apply to your

particular situation and follow them explicitly.

When the Classic II is mounted on a truck or a trailer,

the machine generator ground stud MUST be secure-

ly connected to the metal frame of the vehicle. See

Figure A.2. The ground stud is marked with the ground

symbol.

For further protection against electric shock, any elec-

trical equipment connected to the generator recepta-

cles must use a three-blade, grounded type plug or an

Underwriter's Laboratories (UL) approved double insu-

lation system with a two-blade plug. Lincoln offers an

accessory plug kit that has the right type of plugs. See

the

Accessories

section of this manual for details.

If you need ground fault protection for hand-held equip-

ment, refer to the

Accessories

section of this manual

for the GFCI Receptacle kit.

AUXILIARY POWER RECEPTACLES,

PLUGS, AND HAND-HELD EQUIPMENT

The AC auxiliary power, supplied as a standard, has a

rating of 3.0 kVA of 115/230V AC (60 hertz).

With the 3.0 kVA, 115/230V AC auxiliary power, one

115V duplex and one 230V grounding type receptacle

are provided. The circuit is protected with circuit break-

ers.

The rating of 3.0 kVA permits a maximum continuous

current of 13 amps to be drawn from the 230 volt

duplex receptacle. Or a total of 26 amps can be drawn

from the 115 volt duplex receptacle. The 115 volt

duplex receptacle has a configuration which permits 15

amps on CSA machines and 20 amps on non-CSA

machines. The total combined load of all receptacles

is not to exceed 3.0 kVA.

CIRCUIT BREAKERS

Classic II welders are equipped with

circuit breakers on the 115 and the

230 volt receptacles for overload pro-

tection. Under high heat a breaker

may tend to trip at lower loads than it would normally.

Operation with high ambient temperatures may cause

the breakers to trip at lower than normal loads.

Never bypass the circuit breakers. Without overload

protection, the Classic II could overheat and/or cause

damage to the equipment being used.

INSTALLATION

A-7 A-7

CLASSIC II

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WARNING

CAUTION

1

FIGURE A.2 - GROUND STUD LOCATION

1. Ground Stud

NOTES

A-8 A-8

CLASSIC II

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Section B-1 Section B-1

CLASSIC II

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications........................................................................................................B-3

Welder .................................................................................................................................B-3

Generator..............................................................................................................................B-3

Operational Features and Controls.............................................................................................B-3

Design Features..........................................................................................................................B-3

Welding Capability ......................................................................................................................B-4

Limitations .................................................................................................................................B-4

Controls and Settings..................................................................................................................B-5

Welder/Generator Controls...................................................................................................B-5

Control of Welding Current...................................................................................................B-6

Diesel Engine Controls:........................................................................................................B-7

Engine Operation........................................................................................................................B-8

Before Starting the Engine ...................................................................................................B-8

Starting the Engine...............................................................................................................B-8

Stopping the Engine.............................................................................................................B-9

Cold Weather Starting..........................................................................................................B-9

Break-in Period.....................................................................................................................B-9

Welding Operation ....................................................................................................................B-10

General Information............................................................................................................B-10

Idler Operation....................................................................................................................B-10

Classic II DC Constant Current Stick or TIG Welding ........................................................B-11

Classic II DC Wire Feed Welding (Constant Voltage)........................................................B-12

Auxiliary Power .........................................................................................................................B-13

Using Auxiliary Power and Welding at the Same Time......................................................B-13

OPERATING INSTRUCTIONS

Read and understand this entire section before operat-

ing your Classic II.

SAFETY INSTRUCTIONS

Do not attempt to use this equipment until you have

thoroughly read all the operation and maintenance

manuals supplied with your machine. They include

important safety precautions; detailed engine starting,

operating, and maintenance instructions; and parts

lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet clothing.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dan-

gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause

fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held

combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust to the outside.

• Do not stack anything on or near the

engine.

MOVING PARTS can injure.

• Do not operate this equipment with any

of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

Only qualified personnel should install, use, or ser-

vice this equipment.

GENERAL DESCRIPTION

The Classic II is a heavy duty engine driven DC arc

welding power source capable of providing constant

current output for stick welding or DC TIG welding. The

Classic II is wound with all copper coils and is config-

ured in a new shorter case with no exciter stickout and

setup for one side service. With the addition of the

optional Wire Feed Module, the Classic II will provide

constant voltage output for running the LN-7 or LN-25.

This unit uses the Deutz F3L-1011F three-cylinder,

industrial air cooled diesel engine.

OPERATION

B-2 B-2

CLASSIC II

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WARNING

RECOMMENDED APPLICATIONS

WELDER

The Classic II provides excellent constant current DC

welding output for stick (SMAW) welding and for DC

TIG welding. It also offers constant voltage output for

DC semiautomatic wire feed welding. For more details

on using the machine as a welder, see

Welding

Operation

in the

Operation

section of this manual.

GENERATOR

The Classic II is also capable of providing 3.0 kVA of

115/230 volts of 60 Hertz AC auxiliary power.

OPERATIONAL FEATURES AND

CONTROLS

The Classic II was designed for simplicity. Therefore,

it has very few operating controls. Two switches are

used for welding operations:

• A five-position CURRENT RANGE SELECTOR

switch selects current output for constant current

stick or TIG applications and constant voltage wire

feed applications (with optional Wire Feed Module -

see the

Accessories

section)

• A FINE CURRENT ADJUSTMENT switch for fine

adjustment of current from minimum to maximum

within each range

Controls for the diesel engine control include a two-

position IGNITION ON/OFF toggle switch, a START

pushbutton, and a two-position IDLER switch that

selects engine speed for welding or auxiliary power

applications. See

Engine Operation

in the

Operation

section of this manual for details about starting, run-

ning, stopping, and breaking in the diesel engine.

DESIGN FEATURES

• Constant current DC Stick welding (SMAW) process

capability with output range from 40 - 325 DC amps.

• Constant current DC TIG Welding with output across

the entire range of settings.

• Work and Electrode welding cable mounting termi-

nals.

• Separate ground stud for safe connection of case to

earth ground.

• Duplex, 230 volt auxiliary power receptacle.

• Duplex, 115 volt auxiliary power receptacles.

• Integrated generator output overload protection

through two 20 amp circuit breakers (CSA versions).

• Electric starting.

• Battery Charging Ammeter.

• Engine Oil Pressure Gauge.

• Engine Hour Meter for determining periodic mainte-

nance.

• Top-of-the-line 28.5 HP Deutz diesel engine.

• Top-mounted 15 gallon (57.0 litter) fuel tank with

convenient top fill.

• All copper alternator windings and high quality insu-

lation for dependable long life.

• Automatic engine shutdown protection for low oil

pressure.

• Automatic engine idler goes to low idle approximate-

ly 15 seconds after welding for greater fuel economy;

includes high idle switch.

OPERATION

B-3 B-3

CLASSIC II

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WELDING CAPABILITY

The Classic II is rated 250 amps, 30 volts constant cur-

rent DC at 60% duty cycle based on a ten minute time

period. Longer duty cycles at lower output currents are

possible.

The current is continuously variable from 40 to 325

amps DC.

LIMITATIONS

• The Classic II is not recommended for any process-

es besides those that are normally performed using

DC stick welding (SMAW) and DC TIG welding.

Specific limitations on using the Classic II for these

processes are described in the Welding Operation

section of this manual. Constant voltage welding is

available with the optional wire feed module.

OPERATION

B-4 B-4

CLASSIC II

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OPERATION

B-5 B-5

CLASSIC II

FIGURE B.1 – OUTPUT CONTROLS

1. CURRENT RANGE SELECTOR

2. FINE CURRENT ADJUSTMENT

3. 230 VOLT RECEPTACLE

4. 115 VOLT RECEPTACLE

5. WELD OUTPUT TERMINAL (–)

6. WELD OUTPUT TERMINAL (+)

7. GROUND STUD

WELDER/GENERATOR CONTROLS

See Figure B.1 for the location of the following fea-

tures:

1. CURRENT RANGE SELECTOR: Selects continu-

ous current output for constant current stick or TIG

applications and constant voltage wire feed applica-

tions. The amperages on the dial correspond to the

average amperages needed for specific Lincoln

welder rods. See

Control of Welding Current

for

more information.

2. FINE CURRENT ADJUSTMENT: Allows fine

adjustment of current within the selected output

range. See

Control of Welding Current

for more

information.

3. 230 VOLT DUPLEX RECEPTACLE: Connection

point for supplying 230 volt power to operate one or

two electrical devices.

4. 115 VOLT DUPLEX RECEPTACLE: Connection

point for supplying 115 volt power to operate one or

two electrical devices.

5. WELD OUTPUT TERMINAL (–) WITH FLANGE

NUT: Provides the connection point for either the

electrode holder or the work cable.

6. WELD OUTPUT TERMINAL (+) WITH FLANGE

NUT: Provides the connection point for either the

electrode holder or the work cable.

7. GROUND STUD: Provides a connection point for

connecting the machine case to earth ground for

the safest grounding procedure.

CONTROLS AND SETTINGS

The welder/generator controls are located on the

Output Control Panel of the machine case front. Diesel

engine idler control and start/stop controls are also on

the case front. Welding output terminals and ground

stud are located on the machine right side, under the

door. See Figure B.1 and the explanations that follow.

3

1

2

6

5

4

7

CONTROL OF WELDING CURRENT

DO NOT turn the CURRENT RANGE SELECTOR

while welding because the current may arc between

the contacts and damage the switch.

See Figure B.2. The CURRENT RANGE SELECTOR

provides five overlapping current ranges. The FINE

CURRENT ADJUSTMENT adjusts the current from

minimum to maximum within each range. Open circuit

voltage is also controlled by the FINE CURRENT

ADJUSTMENT, permitting control of the arc character-

istics.

A high open circuit voltage setting provides the soft

"buffering" arc with best resistance to pop-outs pre-

ferred for most welding. To get this characteristic, set

the CURRENT RANGE SELECTOR to the lowest set-

ting that still provides the current you need and set the

FINE CURRENT ADJUSTMENT near maximum. For

example: to obtain 175 amps and a soft arc, set the

CURRENT RANGE SELECTOR to the 190 -120 posi-

tion and then adjust the FINE CURRENT ADJUST-

MENT for 175 amps.

When a forceful "digging" arc is required, usually for

vertical and overhead welding, use a higher CURRENT

RANGE SELECTOR setting and lower open circuit

voltage. For example: to obtain 175 amps and a force-

ful arc, set the CURRENT RANGE SELECTOR to 240-

160 position and the FINE CURRENT ADJUSTMENT

setting to get 175 amps.

Some arc instability may be experienced with EXX10

electrodes when trying to operate with long arc tech-

niques at settings at the lower end of the open circuit

voltage range.

DO NOT attempt to set the CURRENT RANGE

SELECTOR between the five points designated on the

nameplate. These switches have a spring loaded cam

which almost eliminates the possibility of setting this

switch between the designated points.

OPERATION

B-6 B-6

CLASSIC II

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CAUTION

FIGURE B.2 – CURRENT CONTROLS

220

MAX.

240-160

190-120

130-80

90

MIN.

90

80

70

60 50

40

30

20

10100

CURRENT RANGE

SELECTION

IDLER IGNITION

START

REMOTE

CONTROL

ENGINE

PROTECTION

C

lassic

115 VOLTAC230 VOLTAC

FINE CURRENT

ADJUSTMENT

FINE CURRENT

ADJUSTMENT

CURRENT

RANGE

SELECTOR

CAUTION

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